Method and apparatus for digital thread inspection

ABSTRACT

A compact inspection assembly comprising digital sensors and/or laser measurement systems to validate attributes of pipe and associated threaded connections. An elongate body member is partially inserted into a central bore of a pipe section. A stabilizing centralizer assembly is selectively expanded to engage against the inner surface of the pipe section and prevent axial and rotational movement of the body section relative to the pipe section. An automated sensor assembly, attached to the body member and positioned in proximity to a threaded connection, measures data regarding the pipe and associated threaded connections. The measured and recorded data can be compared to predetermined standards (such as, for example, original equipment manufacturer and/or end user specifications or requirements) to verify pipe/connection compliance with desired standards.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention comprises a method and apparatus for comprehensivedigital inspection of pipe sections and other tubular goods including,without limitation, threaded connections thereof. More particularly, thepresent invention comprises a method and apparatus for comprehensivedigital inspection of pipe sections and other tubular goods, as well asassociated threaded connections, in order to measure a variety of dataincluding, without limitation, tube length, inside diameter (“ID”) andouter diameter (“OD”), and threaded connection data and characteristics.More particularly still, the present invention comprises a method andapparatus for comprehensive digital inspection of pipe sections andother tubular goods, as well as associated threaded connections,utilizing some combination of integrated laser measurement, opticalsensors, phased-array and/or UT technology.

2. Brief Description of the Prior Art

Pipe (such as, for example, casing, drill pipe and/or other tubulargoods) is commonly used in the oil and gas industry, as well as otherapplications. Such pipe is typically utilized in sections having alength of thirty feet or more, as well as various length pup joints,accessories or other components that may be utilized in a pipe stringdesign. Each pipe section—commonly referred to as a “joint”—typicallyhas a threaded connection disposed at each axial end. In some cases, apipe section has one male or “pin-end” connection at one end, and afemale or “box-end” connection at the other end. In other cases, pipesections have male or pin-end connections at both ends and can be joinedtogether using an internally threaded coupling or collar member.

In order to ensure safety and operational integrity, such pipe sectionsand the associated threaded connections are routinely inspected forquality assurance purposes. Conventional thread inspection methods aretypically performed using an inspector's naked eye—the inspectorvisually inspects a pipe section and its threaded connections, andthereafter assigns a qualitative grade or rating to said connectionsbased on the inspector's visual observation and subjectivedetermination.

Such visual thread inspection, commonly referred to as “VTI”, suffersfrom a number of significant limitations. Grading can vary betweeninspectors, and external conditions and/or environmental factors canalso impact the quality of VTI and the associated results. Put anotherway, such conventional VTI methods rely entirely on human interactionand interpretation for accuracy and compliance; as such, saidconventional methods of VTI can be inconsistent and subject to humanerror. In some cases, improperly inspected or inconsistently gradedthreaded connections can result in problems (which can sometimes becatastrophic) when pipe is subsequently used during operations.

Thus, there is a need for an improved method and apparatus forinspecting pipe sections including, without limitation, threadedconnections thereof. Such improved method and apparatus should accountfor differences in environmental conditions, while reducing—if notentirely eliminating—human error and inspector subjectivity. Further,such improved method and apparatus should be effective, as well asrelatively inexpensive and easy to deploy and utilize.

SUMMARY OF THE PRESENT INVENTION

The present invention comprises a method and apparatus for digitalinspection of pipe sections and associated threaded connections. In apreferred embodiment, the present invention comprises a compact and easyto use inspection assembly employing digital imaging and lasermeasurement systems to validate desired attributes of a threaded pipeconnection including, without limitation, verification against knownstandards (such as, for example, original equipment manufacturer [“OEM”]and/or end user specifications). Further, the method and apparatus ofthe present invention utilizes specifically calibrated equipment toverify threaded connection characteristics without requiring or relyingon human subjectivity for accuracy and compliance.

In a preferred embodiment, the digital inspection assembly of thepresent invention comprises a substantially cylindrical elongate bodymember. A selectively expandable centralizer assembly is attached tosaid elongate body member and can alternate between a first “collapsed”position and second “extended” position. In said first collapsedposition, said centralizer assembly is positioned against or inrelatively close proximity to the outer surface of said elongate bodymember. In said second extended position, said centralizer assembly isexpanded radially outward from said elongate body member in order toengage against the inner surface of a pipe section.

A digital sensor mounting assembly having a plurality of digitalcameras, laser optics (such as 2D/3D laser digital sensors) and/oroptical digital sensors is rotatable relative to said central elongatebody member for obtaining optical images of (male or female) threadedconnections. In a preferred embodiment, said digital sensor assembly ispositioned in proximity to a threaded connection and can be rotated 360degrees about a longitudinal axis of said central elongate body member,thereby permitting said digital sensor assembly to inspect the entirecircumference of a threaded connection.

The digital inspection assembly of the present invention can bemotorized, allowing for automated rotation at a constant or adjustablerotational speed. Additionally, controlled lighting and imaging systemsprovide for enhanced accuracy and calibrated imaging. The digitalinspection assembly of the present invention can accommodate pipe andother tubular goods having virtually any diameter.

Further, in a preferred embodiment, said digital inspection assemblyprovides for self-centering, auto-focus and desired alignment relativeto a pipe section and associated threaded connection. Although othermethods can be envisioned without departing from the scope of thepresent invention, such functions are controlled using ComputerNumerically Controlled (“CNC”) software and control systems.

An automated laser length and pipe diameter measurement system, whichcan also be controlled by custom-designed software, utilizes at leastone laser measurement tool and permits accurate measurement of pipesection length, internal diameter and pipe ovality. When two opposingdigital inspection assemblies are utilized (one at each end of a pipesection), said two-station system can be synced with each other forinspection optimization. In such scenarios, multiple threadedconnections can be inspected simultaneously, with lighting, imaging,motor automation and laser applications working together, while beingcontrolled from a common or central control panel.

The digital inspection assembly of the present invention can beportable, allowing for mobile deployment and use at virtually anylocation (such as, for example, pipe yards, mills, rigs, remote or otherlocations). In an alternative embodiment, said digital inspectionassembly can be hand held, mounted to a temporary support structure, orpermanently supported. Modular design of the digital inspection assemblyallows for incorporation of additional components and complete remoteautomation.

Measured data can be utilized with an automated pipe grade verificationsystem, and/or stored on a cloud-based data storage system. Further,such measured data can be accessed for comparison and/or verificationthat: connection attributes are within OEM or other standards foracceptable connection tolerances, ovality is within desired API or otherspecifications or standards, and/or connection tolerances for mating pinand box connections will ensure optimal connection performance inoperation. Additionally, data from laser topography and/or digitaloptical sensor(s) can verify that any defects are within acceptabletolerances relative to OEM specifications and/or other applicablestandards.

Additionally, real time data acquisition and Wi-Fi connectivity allowsfor remote viewing of measured data worldwide (including, withoutlimitation, GSM, 3G, 4G, Bluetooth, Wi-Fi, satellite and/or cablednetworks). PDF or other specific application conversion of all images,lengths, defects, acceptance criteria and all system set up parametersfor electronic report generation and delivery. Said assembly canbeneficially operate off of external power and does not require aninternal battery for operation.

The digital inspection assembly of the present invention can permitinspection of multiple attributes of male and/or female threadedconnections including, without limitation, the following: thread image,nose image, seal area, shoulders, relief grooves, roots, crests, pitch(including variable pitch), diameter, pipe OD, pipe ID, pipe ovalityand/or other measurable variables. A report containing captured data andany analysis can be automatically generated and forwarded to desiredrecipients. Connection inspection information can be numbered,time-stamped and dated.

In a preferred embodiment, the digital inspection assembly of thepresent invention can be operated and utilized by a single person.Further, the digital inspection assembly is accurately repeatable (i.e.duplicate inspections of the same pipe/connection will yield identicalresults within measurement tolerances).

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description ofthe preferred embodiments, is better understood when read in conjunctionwith the appended drawings. For the purpose of illustrating theinvention, the drawings show certain preferred embodiments. It isunderstood, however, that the invention is not limited to the specificmethods and devices disclosed. Further, dimensions, materials and partnames are provided for illustration purposes only and not limitation.

FIG. 1 depicts a side view of a digital inspection assembly of thepresent invention having a centralizer assembly in a substantiallycollapsed configuration.

FIG. 2 depicts a rear perspective view of a digital inspection assemblyof the present invention having a centralizer assembly in asubstantially collapsed configuration.

FIG. 3 depicts a front perspective view of a digital inspection assemblyof the present invention having a centralizer assembly in asubstantially collapsed configuration.

FIG. 4 depicts a side view of a digital inspection assembly of thepresent invention having a centralizer assembly in a substantiallyextended configuration.

FIG. 5 depicts a rear perspective view of a digital inspection assemblyof the present invention having a centralizer assembly in asubstantially extended configuration.

FIG. 6 depicts a front perspective view of a digital inspection assemblyof the present invention having a centralizer assembly in asubstantially extended configuration.

FIG. 7 depicts a side view of a digital inspection assembly of thepresent invention having a centralizer assembly in a substantiallycollapsed configuration being inserted into the central bore of a pipesection.

FIG. 8 depicts a rear perspective view of a digital inspection assemblyof the present invention having a centralizer assembly in asubstantially collapsed configuration being inserted into the centralbore of a pipe section.

FIG. 9 depicts a front perspective view of a digital inspection assemblyof the present invention having a centralizer assembly in asubstantially collapsed configuration being inserted into the centralbore of a pipe section.

FIG. 10 depicts a rear perspective and partial cut-away view of adigital inspection assembly of the present invention having acentralizer assembly in a substantially collapsed configuration afterbeing inserted into the central bore of a pipe section.

FIG. 11 depicts a rear perspective view and partial cut-away view of adigital inspection assembly of the present invention having acentralizer assembly in a substantially extended configuration afterbeing inserted into the central bore of a pipe section.

FIG. 12 depicts a side and partial cut-away view of a digital inspectionassembly of the present invention having a centralizer assembly in asubstantially extended configuration after being inserted into thecentral bore of a pipe section.

FIG. 13 depicts a side view of a digital inspection assembly of thepresent invention after being inserted into a central bore of a pipesection.

FIG. 14 depicts a side view of a digital inspection assembly of thepresent invention after being inserted into a central bore of a pipesection during digital inspection of a threaded connection.

FIG. 15 depicts a rear perspective view of a digital inspection assemblyof the present invention after being inserted into a central bore of apipe section during digital inspection of a threaded connection.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION

FIG. 1 depicts a side view of a digital inspection assembly 100 of thepresent invention in a substantially collapsed position. Digitalinspection assembly 100 generally comprises central body or tube member20 attached to handle assembly 50. In a preferred embodiment, tubemember 20 and handle assembly 50 are attached in axial alignment witheach other, but are capable of relative rotation about said commonlongitudinal axis.

Centralizer assembly 30 is generally disposed along the outer surface ofsaid central tube member 20. Said centralizer assembly 30 can beselectively alternated between a first retracted or “collapsed”(radially inward) position as depicted in FIG. 1, and a second“extended” (radially outward) position, as depicted in FIG. 4, forexample, and more fully described below.

Linear mounting arm 90 is fixedly attached to handle assembly 50. In apreferred embodiment, the longitudinal axis of linear mounting arm 90 isdisposed substantially perpendicular orientation to the alignedlongitudinal axes of handle assembly 50 and central tube member 20.Digital sensor mounting assembly 80 is slidably disposed on elongatetrack member 92 formed by linear mounting arm 90; said digital sensormounting assembly 80 can be moved along the length of said linearmounting arm 90 between handle assembly 50 and distal end 91, andselectively secured or locked in place at a desired position along thelength of said track member 92.

In a preferred embodiment, digital sensor mounting assembly 80 forms asubstantially U-shaped structure having first leg member 81, second legmember 82 and inner crown section 83. Further, in said preferredembodiment, said first leg member 81 and second leg member 82 areoriented substantially parallel to each other, defining throat area 84extending into a gap or space formed between said first leg member 81and second leg member 82.

Stepper motor 60 is attached to central tube member 20, while rotationgear 70 is attached to handle assembly 50. Said stepper motor 60 rotatesa drive gear (not depicted in FIG. 1) operationally engaged withrotation gear 70; actuation of said stepper motor 60 results inapplication of torque forces to handle assembly 50, thereby causinghandle assembly 50 to rotate about is longitudinal axis, even whencentral tube member 20 remains stationary and/or is prevented fromrotation relative to said handle assembly 50.

FIG. 2 depicts a rear perspective view of a digital inspection assembly100 of the present invention in a substantially collapsed position,while FIG. 3 depicts a front perspective view of said digital inspectionassembly 100. Digital inspection assembly 100 generally comprisescentral tube member 20 attached to handle assembly 50. Tube member 20and handle assembly 50 are attached in axial alignment with each other,but are capable of rotation relative to each other about a commonlongitudinal axis.

Centralizer assembly 30 is disposed along the outer surface of saidcentral tube member 20. As depicted in FIGS. 2 and 3, said centralizerassembly 30 is illustrated in a first “collapsed” (radially inward)position. In a preferred embodiment, said centralizer assembly 30comprises stationary collar 31 (not visible in FIG. 2), traveling collar32, upper rib members 33, lower rib members 34, pusher rib members 35and outer pad members 36.

Although the specific design of said pad members 36 can vary withoutdeparting from the scope of the present invention, in a preferredembodiment said pad members 36 further comprise a substantially convexor curved outer surface area, as well as tapered and substantiallyinwardly-facing nose section 37. Traveling collar 32 is automaticallypositioned and disposed on the outer surface of central tube member 20and can move along at least a portion of the length of said tube member20.

Linear mounting arm 90 is fixedly attached to handle assembly 50, and isdisposed in substantially perpendicular orientation to the alignedlongitudinal axes of handle assembly 50 and central tube member 20.Digital sensor mounting assembly 80 is slidably disposed on linearmounting arm 90 and forms a substantially U-shaped structure havingfirst leg member 81, second leg member 82 and inner crown section 83.

In a preferred embodiment, measurement notations or ruler indicia can bedisplayed on said linear mounting arm 90 and can reflect positioning ofdigital mounting assembly 80 relative to said linear mounting arm; forexample, said ruler indicia can correspond to predetermined pipediameter measurements.

Stepper motor 60 is attached to central tube member 20, while rotationgear 70 is attached to handle assembly 50. Said stepper motor 60 rotatesa drive gear (not depicted in FIG. 2 or 3) operationally engaged withrotation gear 70; actuation of said stepper motor 60 results inapplication of torque forces to handle assembly 50, thereby causinghandle assembly 50 to rotate about is longitudinal axis relative toadjacent central tube member 20.

Still referring to FIGS. 2 and 3, a plurality of sensors 45 are disposedalong the inner surfaces of first leg member 81 (not visible in FIGS. 2and 3), second leg member 82 and inner crown section 83 of digitalsensor mounting assembly 80. Specific placement, positioning,orientation and focus of said sensors 45 can vary by application andintended use, but it is to be observed that said sensors 45 aregenerally directed or focused on a threaded connection of a pipesection.

By way of illustration, but not limitation, said sensors 45 can comprisedigital cameras, digital sensors, image sensors, laser sensors or somecombinations thereof. Additionally, lighting elements (such as, forexample, a local diffused LED strip) can be provided on first leg member81, second leg member 82, inner crown section 83 and/or handle assembly50 to illuminate and direct additional light in the direction of athreaded connection being inspected by the apparatus of the presentinvention.

FIG. 4 depicts a side view of a digital inspection assembly 100 of thepresent invention with centralizer assembly 30 in a substantiallyextended position. FIG. 5 depicts a rear perspective view of digitalinspection assembly 100 of the present invention, while FIG. 6 depicts afront perspective view of said digital inspection assembly 100, withcentralizer assembly 30 in a substantially extended position.

Referring to FIGS. 5 and 6, a fluid powered cylinder (such as, forexample, a pneumatic or hydraulic powered cylinder) having a selectivelyextendable/retractable piston rod 21 is disposed within the inner boreor chamber of central tube member 20. Mounting bracket member 22 isdisposed at the distal end of piston rod 21, while a plurality of clevisbrackets 23 are disposed on said mounting bracket member 22. Lower ribmembers 34 are pivotally attached at one end to said clevis brackets 23using pivot pins 24; said lower rib members 34 are pivotally attached topusher rib members 35 (at the opposite end from said mounting bracketmember 22) using pivot pins 25. Pusher rib members 35 are, in turn,pivotally attached to travelling collar 32 using pivot pins 26.

Still referring to FIGS. 5 and 6, selective extension of piston rod 21forces mounting bracket member 22 in a direction away from central tubemember 20. As said piston rod 21 is extended in this manner, force isapplied to lower rib members 34. Such force is, in turn, applied topusher rib members 35 and traveling collar 32, thereby causing saidtraveling collar to move axially along the length of said central tubemember 20 in a direction that is generally away from stationary collar31. Such action results in pad members 36 (including tapered nosesection 37) being extended radially outward relative to the outersurface of said central tube member 20.

FIG. 7 depicts a side view of a digital inspection assembly 100 of thepresent invention in a substantially collapsed position being insertedinto pipe section 200. FIG. 8 depicts a rear perspective view of saiddigital inspection assembly 100 of the present invention in asubstantially collapsed position being inserted into said pipe section200, while FIG. 9 depicts a front perspective view of said digitalinspection assembly 100 being inserted into said pipe section 200.

Referring to FIG. 8, pipe section 200 further comprises central bore201, outer or external surface 202, inner surface 203 defined by saidcentral bore 201 and external threads 204 disposed on a portion of saidouter surface 202. Nose or end section 205 is formed by threads 204.Although said external threads 204 are depicted in FIGS. 7 through 9 asa male or “pin-end” threaded connection, it is to be observed that saidthreads can also comprise a female or “box-end” threaded connectionwithout departing from the scope of the present invention.

Still referring to FIG. 8, although not visible in FIG. 8, piston rod 21is substantially retracted causing mounting bracket member 22 to bepositioned at or near central tube member 20. Lower rib members 34 acton pusher rib members 35 which, in turn, act on traveling collar 32,thereby forcing said traveling collar 32 axially along the length ofsaid central tube member 20 in a direction that is generally towardstepper motor 60. Such action results in pad members 36 collapsingradially inward relative to the outer surface of said central tubemember 20. In such a collapsed position, inwardly facing tapered nosesections 37 of pad members 36 cooperate to form a generally conicalconfiguration, thereby acting as guides to help direct digitalinspection assembly 100 into central bore 201 and prevent said padmembers 36 from getting caught or “snagged” on pipe section 200.

FIG. 10 depicts a rear perspective and partial cut-away view of digitalinspection assembly 100 of the present invention in a substantiallycollapsed position after being inserted into central bore 201 of pipesection 200. With centralizer assembly 30 in this “collapsed” orretracted configuration, a portion of digital inspection assembly 100can be inserted or received within central bore 201 of pipe section 200.As depicted in FIG. 10, when said digital inspection assembly 100 ispartially received within said central bore 201, a portion of threads204 (including nose 205) are received within substantially U-shapedstructure of digital sensor mounting assembly 80; more specifically, aportion of said threads 204 are positioned between first leg member 81and second leg member 82. Nose section 205 is generally positioned inproximity to inner crown section 83.

FIG. 11 depicts a rear perspective and partial cut-away view of digitalinspection assembly 100 of the present invention with centralizerassembly 30 in a substantially extended or expanded configuration afterbeing inserted into central bore 201 of a pipe section 200. After saiddigital inspection assembly 100 is installed a desired distance withinsaid central bore 201, selective extension of piston rod 21 forcesmounting bracket member 22 away from central tube member 20 (that is, ina direction generally away from stepper motor 60).

In a preferred embodiment, said centralizer assembly 30 is a mechanicalsystem that uses a combination of adjustable lever arm/rib assemblies,together with collars, to reliably centralize central tube member 20relative to the inner surface 203 of a pipe section 200. As discussedherein, the diameter of said centralizer assembly 30 can be selectivelyincreased and decreased. Specifically, as said piston rod 21 isselectively extended, force is applied to lower rib members 34, pusherrib members 35 and traveling collar 32, thereby causing said travelingcollar 32 to move axially along the length of said central tube member20 in a direction that is generally away from stepper motor 60. Suchaction results in pad members 36 extending radially outward relative tothe outer surface of said central tube member 20 until said pad members36 contact inner surface 203 of pipe section 200.

In a preferred embodiment, the curvature of the outer surfaces of saidpad members 36 substantially conform to the curvature of the innersurface 203 of pipe section 200. The relatively large/increased surfacearea of said pad members 36, contact area between said pad members 36and inner surface 203, and radially outward force applied to said padmembers 36 by centralizer assembly 30 collectively results in creationof substantial frictional forces between said pad members 36 and pipesection 200, thereby securing digital inspection assembly 100 againstaxial and radial movement relative to pipe section 200. Once engagedagainst pipe section 200 as depicted in FIG. 11, said centralizerassembly 30 is configured to self-lock when pressure is applied so thatthe system remains rigid, axially stationary and does not roll or rotatealong inner surface 203 of pipe section 200.

FIG. 12 depicts a side and partial cut-away view of a digital inspectionassembly 100 of the present invention in a substantially extendedposition after being partially inserted into central bore 201 of a pipesection 200. As depicted in FIG. 12, when said digital inspectionassembly 100 is partially received within said central bore 201 andcentralizer assembly 30 is extended so that pad members 36 engageagainst inner surface 203 of pipe section 200, said digital inspectionassembly 100 is secured against axial and radial movement relative tosaid central bore 201.

Digital sensor mounting assembly 80 can be selectively positioned alongthe length of linear mounting arm 90 so that a portion of threads 204(including nose 205) of pipe section 200 are received withinsubstantially U-shaped structure of digital sensor mounting assembly 80(that is, between substantially parallel and opposing first leg member81 and second leg member 82). Nose section 205 of threads 204 of pipesection 200 is generally positioned in proximity to inner crown section83 of sensor mounting assembly 80.

FIG. 13 depicts a side (non-cutaway) view of said digital inspectionassembly 100 after being partially inserted into a central bore of apipe section. When said digital inspection assembly 100 is partiallyreceived within said central bore 201, digital sensor mounting assembly80 can be selectively positioned along the length of linear mounting arm90 so that a portion of threads 204 (including nose 205) of pipe section200 are received within substantially U-shaped structure of digitalsensor mounting assembly 80 between substantially parallel and opposingfirst leg member 81 and second leg member 82. Nose section 205 ofthreads 204 of pipe section 200 is generally positioned in proximity toinner crown section 83 of sensor mounting assembly 80.

FIG. 14 depicts a side view of digital inspection assembly 100 of thepresent invention during digital sensing of threads 204 and nose section205 of pipe section 200. FIG. 15 depicts a rear perspective view ofdigital inspection assembly 100 after being partially inserted intocentral bore 201 of pipe section 200 during digital sensing of threadedconnection 204 (including, without limitation, nose section 205) of pipesection 200.

Referring back to FIG. 12, handle assembly 50 comprises housing 51 forenclosing at least one microcontroller, electronics, processors, wiringand circuitry used to control various components and functions ofdigital inspection assembly 100 including, without limitation, motordriver interaction, local controls, sensor data routing, and localindication. Additionally, said handle assembly 50 includes electronicsensors that can be used to determine pipe length and pipe ID, asdiscussed below. At least one integrated handle grip member 52 permitseasy and convenient transportation and/or manipulation of digitalinspection assembly 100 during use and/or between operation of saidapparatus.

Referring to FIG. 11, at least one sensor 45 used for data acquisitionis disposed within first leg 81, second leg 82 and inner crown section83 of digital sensor assembly 80. In a preferred embodiment, an array orplurality of sensors 45 can be used to capture visual images of longthreads 204, and to eliminate any distortion due to perspective. By wayof illustration, but not limitation, such sensors can comprise E-ConSystem's 5MP camera-board eCAM51, and/or a OV5640 CMOS sensor that cancapture up to a 5MP photo. Additionally, such sensors 45 canbeneficially include an autofocus feature for electronically adjustingfocus to prevent any need for manual intervention or focusing.

Referring to FIG. 11, at least one laser distance sensor 42 canselectively measure distance and pipe ovality from handle memberassembly 50 to inner surface 203 of pipe section 200; said sensor 42 canmeasure pipe ID. By way of illustration, but not limitation, said laserdistance sensor 42 can accurately measure distances between 50 mm and350 mm or more with a resolution of 0.05 mm. Referring to FIG. 9, atleast one laser distance sensor 41 can also measure the length of pipesection 200 with a resolution of 0.02 mm. In certain applications, areflector can be utilized at the opposite end of pipe section 200 fromdigital inspection assembly 100 for measurement accuracy.

In operation, tubular goods (such as pipe section 200) and connectionsare cleaned, prepared for a digital inspection process and, whennecessary, moved to an inspection station. Digital inspection assembly100 can be calibrated in accordance with applicable specifications orpredetermined standards. Pipe or other tubular goods can be moved into adesired position for digital thread inspection by mechanical or humanintervention. In a preferred embodiment, integrated and automated rackswith centering devices can be utilized, including a 3-pointstabilization system to alleviate bending moments in said pipe or othertubular goods.

Referring to FIG. 10, digital inspection assembly 100 is partiallyreceived within said central bore 201 of pipe section 200. Referring toFIG. 11, centralizer assembly 30 is selectively extended so that padmembers 36 engage against inner surface 203 of pipe section 200; in thismanner, central body member 20 of said digital inspection assembly 100is centralized within said bore 201 and secured against axial and radialmovement relative to said central bore 201.

Still referring to FIG. 11, digital sensor mounting assembly 80 isselectively positioned along the length of linear mounting arm 90 sothat a portion of threads 204 (including nose 205) of pipe section 200are received within substantially U-shaped structure of digital sensormounting assembly 80 (that is, between substantially parallel andopposing first leg member 81 and second leg member 82). Nose section 205of threads 204 of pipe section 200 is generally positioned in proximityto inner crown section 83 of sensor mounting assembly 80.

Once secured in this manner, digital thread inspection assembly 100 ofthe present can begin the thread inspection process. Specifically,stepper motor 60 can be selectively actuated to drive rotation gear 70,thereby causing handle assembly 50 and attached sensor mounting assembly80 to rotate relative to stationary central body member 20. Suchrotation permits sensor mounting assembly 80 to rotate 360-degrees,thereby permitting sensors 45 to acquire data around the fullcircumference of threaded connection 204.

The present invention can engage pin and box connections simultaneouslythrough remote automation. Proprietary software properly aligns thedigital thread inspection assembly with said connections for optimalimaging and laser sensing and data acquisition. The automated digitalthread inspection assembly 100 of the present invention can capture a360-degree image and sense data to verify the attributes of pipe ID, OD,pin nose, seal areas, threaded areas, box face, coupling face, ovality,laser length, and pipe ID measurements of a pipe section or tubular inreal time.

The digital thread inspection assembly of the present invention cancapture connection images with digital cameras, lasers scanners orsensors, ultrasonic transducer(s) (‘UT”) and/or phased array technologyvia the custom designed automated rotation device. Recorded data can betransmitted real time via cables or wireless transmission to a controlstation and/or to remote monitoring stations. Said control stationhouses the computer systems and monitors, with all peripheral equipmentassociated with the apparatus of the present invention.

Proprietary software can compare all measured or input data againstpredetermined standards or specifications to verify that all attributesare within OEM specifications. Defects noted can be highlighted andreferenced on an image to show position on the screen in relation toAzimuth headings on a pipe section or tubular good for quickverification. Defects noted can be stored and all repairs re-scanned andcompared to a predetermined OEM standard

Software will automatically store all measured or input data receivedand compare such data to the standard for a “real time” go/no-godetermination. Additionally, a mobile application can be implemented foradditional remote access and monitoring. When two opposing digitalinspection assemblies are utilized (one at each end of a pipe section),said two-station assemblies can be synced with each other for inspectionoptimization. In such scenarios, multiple threaded connections can beinspected simultaneously, with lighting, imaging, motor automation andlaser applications working together, while being controlled from acommon or central control panel.

The digital inspection assembly of the present invention can beportable, allowing for mobile deployment and use at virtually anylocation (such as, for example, pipe yards, mills, rigs, remote or otherlocations). In alternative embodiments, said digital inspection assemblycan be hand held, mounted to a temporary support structure, orpermanently supported via an automated and/or robotic arm structure.

Measured data can be stored and utilized with an automated pipe gradeverification system, and/or stored on a cloud-based data storage system.Further, such measured data can be accessed for comparison and/orverification of multiple conditions including, without limitation, thatthreaded connection attributes are within OEM or other predeterminedstandards for acceptable connection tolerances, that ovality is withindesired API or other specifications or standards, and/or that connectiontolerances for mating pin and box connections will ensure optimalconnection performance in operation. Additionally, data from lasertopography and/or digital optical sensor(s) can verify that any defectsare within acceptable tolerances relative to OEM specifications and/orother applicable standards.

Additionally, real time data acquisition and Wi-Fi connectivity allowsfor remote viewing of measured data worldwide (including, withoutlimitation, GSM, 3G, 4G, Bluetooth, Wi-Fi, satellite and/or cablednetworks). PDF or other specific application conversion of all images,lengths, defects, acceptance criteria and all system set up parametersfor electronic report generation and delivery. Said assembly canbeneficially operate off of external power and does not require aninternal battery for operation.

The digital inspection assembly of the present invention can permitinspection of multiple attributes of male and/or female threadedconnections including, without limitation, the following: thread image,nose image, seal area, shoulders, relief grooves, roots, crests, pitch(including variable pitch), diameter, pipe OD, pipe ID, pipe ovalityand/or other measurable variables. A report containing captured data andany analysis can be automatically generated and forwarded to desiredrecipients. Connection inspection information can be numbered,time-stamped and dated.

In a preferred embodiment, the digital inspection assembly of thepresent invention can be operated and utilized by a single person.Further, the digital inspection assembly is accurately repeatable (i.e.duplicate inspections of the same pipe/connection will yield identicalresults within measurement tolerances).

The above-described invention has a number of particular features thatshould preferably be employed in combination, although each is usefulseparately without departure from the scope of the invention. While thepreferred embodiment of the present invention is shown and describedherein, it will be understood that the invention may be embodiedotherwise than herein specifically illustrated or described, and thatcertain changes in form and arrangement of parts and the specific mannerof practicing the invention may be made within the underlying idea orprinciples of the invention.

What is claimed:
 1. A digital inspection apparatus for inspecting athreaded connection of a pipe section comprising: a) a robotic armassembly; b) a sensor mounting assembly operationally attached to saidrobotic arm assembly, wherein said sensor mounting assembly comprises asubstantially U-shaped member having a first leg and a second leg,wherein said first and second legs are positioned in substantiallyparallel orientation to each other and define a gap configured toreceive a portion of said threaded connection; and c) at least one dataacquisition sensor operationally attached to said sensor mountingassembly and configured to acquire data regarding said threadedconnection.
 2. The apparatus of claim 2, wherein said acquired datacomprises at least one optical image of threads, thread nose, seal area,shoulders, relief grooves, roots, crests, pitch (including variablepitch), pipe outer diameter, pipe inner diameter, pipe ovality or somecombination thereof.
 3. The apparatus of claim 2, wherein said at leastone data acquisition sensor comprises a digital camera, laser scanner,optical sensor, ultrasonic transducer, or some combination thereof. 4.The apparatus of claim 2, wherein said at least one data acquisitionsensor is oriented in a phased array.
 5. A method for inspecting athreaded connection of a pipe section comprising: a) providing a digitalinspection assembly, wherein said digital inspection assembly comprises:i) a robotic arm assembly; ii) a sensor mounting assembly operationallyattached to said robotic arm assembly, wherein said sensor mountingassembly comprises a substantially U-shaped member having a first legand a second leg, wherein said first and second legs are positioned insubstantially parallel orientation to each other and define a gapconfigured to receive a portion of said threaded connection; and iii) atleast one data acquisition sensor operationally attached to said sensormounting assembly and configured to acquire data regarding said threadedconnection; b) acquiring data regarding said threaded connection usingsaid at least one data acquisition sensor; and c) rotating said dataacquisition assembly relative to the longitudinal axis of said pipesection.
 6. The method of claim 5, wherein said acquired data comprisesat least one optical image of threads, thread nose, seal area,shoulders, relief grooves, roots, crests, pitch (including variablepitch), pipe outer diameter, pipe inner diameter, pipe ovality or somecombination thereof.
 7. The method of claim 5, wherein said at least onedata acquisition sensor comprises a digital camera, laser scanner,optical sensor, ultrasonic transducer, or some combination thereof. 8.The method of claim 5, wherein said at least one data acquisition sensoris oriented in a phased array.
 9. The method of claim 5, furthercomprising measuring the length, the internal diameter or ovality ofsaid pipe section using at least one laser measurement tool.
 10. Themethod of claim 5, further comprising comparing data acquired using saidat least one data acquisition sensor against predetermined value.